Contoured packaging and shipping container



Oct. 28, 1969 B. wH RTofi, JR 3,474,950

CONTOURED PACKAGING AND SHIPPING CONTAINER Filed Nov. 9, 1967 2 Sheets-Sheet 1 United States Patent 9 F U.S. Cl. 22923 8 Claims ABSTRACT OF THE DISCLOSURE A shipping container of paperboard stock formed in joined straight sections contoured to approximate the shape of curved items to be boxed, the container sections being self-sustaining in fastened together configuration and stackable one upon the other leaving openings between them for insertion of lift-truck forks for mechanical handling of the containers and contents while conserving, materially, space requirements for shipping and storage.

BACKGROUND OF THE INVENTION Curved objects have generally been difiicult to package except in a rectangular carton which is of the size to encompass all of the projected space of the curved item. Bent sections of tubing, as for example pneumatic message carrying tubing, have rather gentle curvature to connect straight sections of piping at 90 to each other. The piping as manufactured must be protected from damage in transit because any denting of the piping would make it unusable. Such curved sections have been banded together, perhaps six or so sections in one package, the ends protected with a cover, and the banded together sections handled in transit manually. Fork lift trucks could not be used to pick up the pipe sections for fear of damaging the same. The incidence of damaged sections so packaged and shipped has run as high as 90% A rectangular box to enclose such sections has two distinct disadvantages: first, that it encompasses so much space not occupied by product; and second, the rectangular boxes, when stacked for storage, do not leave any spaces for the insertion of fork lift truck arms for mechanically handling the packaged goods.

SUMMARY OF THE INVENTION The present invention provides a contoured box for curved or irregularly shaped items. The box sections are square in section or rectangular, i.e., a four-sided box section, as most paperboard boxes are. The sections, however, are connected one to the other so that their lengths are at obtuse angles to each other. The particular angle chosen is to approximate the curvature of the item being packaged. It may be thought of as box sections approximating chords of the curved item. When the box sections are connected, they are self-sustaining. The contoured boxes are stackable, and in such storage automatically provide convenient spaces for the insertion of fork lift truck arms for mechanically handling the packaged products.

BRIEF DESCRIPTION OF THE DRAWINGS FIGURE 1 is a side elevational view of three contoured containers of the present invention in stacked relation, one of the boxes being cut away at one end to show the curved product therein.

FIGURE 2 is an end elevational view of the stacked containers shown in FIGURE 1.

FIGURE 3 is a cross-sectional view looking into the end of one of the containers taken substantially along line 33 in FIGURE 1.

FIGURE 4 is a fragmentary upright sectional view through the center of one of the connecting areas between box sections of one of the containers in FIGURE 1.

r 3,474,950 Patented Oct. 28, 1969 FIGURE 5 is a plan view of the paperboard blank scored and cut to form the center section of the container shown in FIGURE 1.

FIGURE 6 is a fragmentary perspective view partially cut away of the connection between the center and one end section of the container shown in FIGURE 1.

DESCRIPTION OF THE PREFERRED EMBODIMENTS The particular contoured shipping container chosen for purposes of illustrating the invention is intended for boxing pneumatic carrier transmission tube bends which connect straight pneumatic conveyor tubing, as for example a straight section rising upwardly and a straight section extending horizontally. For weight and handling purposes, about six such tubes are tied together prior to packaging. A rectangular box to enclose such six tubes would have to be about four feet high, seven feet long and one foot wide. Quite obviously, a great deal of space within the box would not be occupied by the tubes.

In FIGURE 1 there is shown a stacked nest of three similar containers 10, 20 and 30 wherein each container is made up of three box sections. The center section of each container is designated A, and the end sections of each container is designated B since they are identical to each other. While the invention is applicable to a two box section container as well as a 3, 4 or 5, etc., all facets of the invention may be illustrated in a three box section container.

When stacked in a warehouse or truck for shipping, the floor F of the warehouse or truck may have timbers 11 placed thereon to support the central section A of the container 30. This leaves a space S into which the arms of a fork lift truck may easily be inserted for lifting and handling the containers. The natural contoured shape of the containers, when stacked as illustrated, leaves a space S-l between containers 20 and 30; likewise available for the insertion of fork lift truck arms, a similar space 8-2 will occur between the containers 10 and 20.

The pneumatic tube bends are shown as they appear in the container 30 in nested groups of tubes 12 and 13. Each group comprises three tubes, as is visible in FIG- URE 3. The tubes rest at their center point 14 upon the bottom of the central box section, and the upper ends of the tubes 15 are closely adjacent the ends of the container in the end sections B. Thus, the contoured container approximates the shape of the curved item being packaged and shipped.

Each B box section is a regular, four-sided paperboard box with flaps to provide an end closure 16 perpendicular to the length of the section, and at the end adjacent the central section A is provided with flaps for interfitting with the central section as shown in FIGURES 4 and 6. In the particular container illustrated, the contoured shape is provided by the formation of the central box section A.

A paperboard or corrugated board box blank as shown in FIGURE 5 is scored and die cut in the usual machinery to place it in a condition to be folded into the appropriate box section A. For example, the blank 21 may have started as a 60-inch square corrugated board blank. In a usual press with an appropriate arrangement of die cutting rails and scoring bars, the blank is scored and die cut. Score lines 22, 23, 24 and 25 are all parallel in order to divide the blank into panels designated #1, #2, #3, #4 and #5. The #1 and #5 panels have a longitudinal length as between the ends 26 and 27 of panel #1, both formed by die cuts. Panel #5 is formed at its ends 28 and 29 by score lines giving panel #5 the same length as panel #1. Panel #3 is to be the bottom of the central box section A and its ends 31 and 32 are formed 3 by score lines giving the panel a longer length than that of panels #1 and #5. When the blank is folded on the longitudinal parallel score lines between panels, panel #1 is placed under panel #5 in face-to-face relationship and glued thereto so that panels #1 and #5 together form the top of the box section. Panels #2 and #4 become the opposite sides of the box extending between the bottom of panel #3 and the top panel.

Each panel of the four-sided box is provided with end flaps to receive mating flaps on the end box sections B. The flaps are all similar, and in this instance since a B box section is secured to each end of the central box section, flaps are provided on each end of each panel. All of the flaps are similar; and the flaps on. the bottom of the box at each end being formed by scored lines 31 and 32. There is an outwardly extending flap portion followed by a fold section between two closely spaced scored lines 33 and 34 followed by an inwardly extending flap portion I. As best seen in FIGURE 6, the flap portion 0 extends outwardly from panel #3 and the inwardly extending part I folds in around the flap 35 on the B box section so that the flaps on the two box sections interlock. Each of panels #2 through are provided with such flaps so that the top, the bottom and each side of the four-sided box will have interfitting flaps between the A and the B box sections.

The difference in length of the bottom and top of the A box section panels determines the relative angle between the A and B sections of the contoured box. It may be noted that the scored lines 36 at the respective ends of panels #2 and #4 of the box are on a bias relative to the parallel score lines between panels. It may also be noted that the flaps extend in a direction perpendicular to the score lines 36. In the particular contoured box illustrated, the angle 37 between the score lines 36 and the adjacent score lines between the bottom and side panels is 55, thereby producing an obtuse angle between the lengths of A and B sections of 125 when assembled. Thus the container in assembled form simulates a contour similar to the curved contour of the contents.

Referring to FIGURES 4 and 6, the interfitting flaps are generally banded about their exterior by a steel band 38 or other fastening element which holds the interfitting flaps together and gives the box sections stability relative to each other. When banded, the box sections are selfsustaining plus the fact that the contents, in the case of metallic tubes, retain their shape and thus aid in holding the box in proper contour shape.

Referring to FIGURE 1, it may be noted that the interfitting flap sections 50 between the A and B box sections appear as enlargements, which in the end view actually extend outwardly from the side walls of the box sections since the flaps are formed on the outside of the containers and add the thickness of corrugated cardboard outwardly from the walls of the container. In addition, these interfitting flaps on the side walls may have extended parts which automatically provide a nesting guide for the stacked containers. For example, in FIGURE 1 the top container has extended parts 51 at each flap section 50 extending down and embracing the B box section of the container below it. A similar arrangement occurs wherein the side flap sections of the container 20 embrace the B box sections of the container 30. This phenomenon is obtained by forming the flaps on side panels #2 and #4 adjacent the bottom panel #3 with an extended part rather than a straight edge, as most of the other flaps are formed. For example, the outwardly extending flap portion 0 on the panel #4 is die cut along a line 41 and the inwardly extending flap portion I is die cut along a line 42 to provide the flap with the extension 51 when folded. These flaps are provided with notches 43 and 44 for the reception of the band 38 so that the band does not distort the outwardly extending character of the folded flaps to provide the nesting guide. Each of the flaps on either end of side panels #2 and #4 is similarly 4 formed with notches to receive the bands, as illustrated in FIGURE 5.

The flaps on top panel 5 are somewhat shortened in width relative to the width of the panel by providing a die out between flaps on the side panel and the top panel along the lines 45 and 46, but this does not decrease the effectiveness of these flaps in joining the central box section A to the end of box sections B. It may be noted that the waste part of the square paperboard blank in FIGURE 5 occurs only in the four corners in the blank between the die cut lines and the dotted outline of the original blank. Thus, very little waste material results. In the event the contoured box consists of but two box sections whose lengths are at an obtuse angle to each other, the flaps at one of the ends of panels, such as 2 through 5 in FIG- URE 5, may be omitted and replaced simply by straight end closure flaps as appear at 16 on the end of the B section of container 30 in FIGURE 1. The angle between box sections may be varied by adjusting the lengths of the panels and thus the size of the angles 37 between the score lines at the longitudinal edges of the bottom panel 3 and the side panels 2 and 4, respectively. Likewise, additional box sections A may be joined together by appropriately forming the flaps to interfit as illustrated in FIGURES 4 and 6.

A great saving in space for shipping odd-shaped articles or items is obtained by the making of a contoured container as herein described. The box sections can be formed relatively inexpensively in that all scores lines and die cuts can be performed on a fiat blank in a press in one operation by appropriately locating the cutting bars and scoring bars in accordance with usual die cutting and scoring procedures.

The foregoing detailed description has been given for clearness of understanding only, and no unnecessary limitations should be understood therefrom, as some modifications may be obvious to those skilled in the art.

I claim:

1. A contoured shipping container for elongated curved items such as bent tubing and the like, comprising:

a plurality of paperboard box sections,

each section being elongated, hollow and of polygonal cross section with longitudinal panels corresponding in number and position to the panels of the other box sections,

each section panel having end flaps for connection of the box sections together by interfolding of mating flaps on corresponding panels,

each flap, relative to its section panel, having a portion extending outwardly and a portion extending inwardly from the extremity of the outwardly extending portion,

said interfolding of said flaps interlocking adjacent section panels together,

said box sections being connected at obtuse angles between their respective lengths forming an elongated container having an interior space approximating the shape of the curved item, and

band securing means about said interconnected flaps securing the box sections together.

2. The shipping container of claim 1 wherein each box section has four panels joined to make a four-sided box of top, bottom and opposite side panels, one section having side panels with its flaps arranged on a bias between the top and bottom panels and the adjoining box section having its flaps square with the top and bottom panels whereby the box section are joined by said flaps determined by the angle of said bias.

3. The shipping container of claim 1 wherein at least three box sections are joined, the center section having its flaps arranged in a plane of reference at an angle to the length of the center section and the flaps on each end section are arranged in a plane of reference generally perpendicular to the length of such section so that each end section is joined to the center section at such obtuse angle.

4. The shipping container of claim 1 wherein three box sections are joined, comprising a center section and two end sections, the center section having a bottom panel and an opposite top panel of shorter length than the bottom panel, said container when stacked with like containers in a position with the end sections extending upwardly rests the bottom of each center section on the end sections of the containers below leaving an opening between stacked containers permitting fork-lift truck arms to be inserted between stacked containers.

5. A contoured container as specified in claim 1 wherein the interfolded flaps of the box sections have exteriorly exposed notches at the extremities of the flaps adjacent flaps on adjoining panels for reception and location of the band securing means.

6. A contoured container as specified in claim 1 wherein the box sections are four-sided with a center section and two end sections joined respectively to the center section simulating chord sections of a curve, the center section having side panel flaps extended outwardly adjacent the bottom of the center section providing exposed flap portions to embrace end box sections of a similar container when such containers are stacked one on top of another.

7. A box blank for a paperboard contoured container, comprising:

a generally rectangular blank scored to fold along spaced parallel lines forming five panels with two outside panels arranged for overlapping to provide a hollow, four-sided box section,

a center panel having ends squared to the panel length and of a greater length than the other panels,

the two outside panels being of comparable length,

shorter than the center panel, and having ends squared to the length of such panels,

two intermediate panels each between the center panel and one outside panel, at least one end of each intermediate panel being a straight line transition between the adjacent end of the center panel and the adjacent end of the outside panel, such transition line thus being at an acute angle to the score lines between panels, and

the ends of each panel except one of the outside panels having flaps extending outwardly perpendicular to the respective ends of the panel, such flaps being scored for folding along lines parallel to the end of its panel whereby the four-sided box, when formed from the blank, has flaps arranged on all four sides of the box section and in a plane of reference at an angle to the longitudinal extent of the box section for receiving an adjoining box section.

8. A box blank as specified in claim 7 wherein the intermediate panels have flaps at both ends thereof at an acute angle to the score lines between panels so that the foursided box section has a flap at each end to receive a box section at each end of such box section.

References Cited UNITED STATES PATENTS 2,569,035 9/1951 Belsinger. 2,981,407 4/1961 Gaulke et al 20662 DAVID M. BOCKENEK, Primary Examiner US. Cl. X.R. 

